Composite molded product and its manufacturing method

Abstract

A composite molded product and its manufacturing method are provided which, when applied to a receiving member for a transport container, can increase the strength of a part that supports an article and reduce manufacturing costs. [Solution] The composite molded product 1a comprises a core material 4 having a structure in which multiple plate materials 2 are integrated by connectors 3, and a skin material 5 formed by vacuum molding using this core material 4 as a mold, and has a structure in which a convex composite molded portion 6a consisting of the core material 4 and the skin material 5 is formed in part of a preform 6 formed by injection molding.

Description

[Technical Field]

[0001] The present invention relates to a vacuum forming method in which a molded object made of a plate-like or sheet material is heated and softened, brought into contact with the surface of a core material having a plurality of small holes, and then the air inside the mold is sucked through the small holes to adsorb the molded object to the surface of the core material.In particular, the present invention relates to a composite molded product consisting of the core material and a skin material formed on the surface of the core material by vacuum forming, and a method for manufacturing the same. [Background technology]

[0002] Containers (hereinafter referred to as transport containers) used for transporting or transporting products, parts, etc. (hereinafter collectively referred to as "items") often have support members installed to prevent the items from being scratched or broken. However, because support members with three-dimensional curved surfaces that conform to the shapes of individual items are often produced in small quantities and in a wide variety of products, traditionally, if all of these support members were to be manufactured by injection molding, it would take a long time to create the molds, resulting in high manufacturing costs.

[0003] To solve these problems, a technology that has attracted attention in recent years is one in which the shape of the part that supports an article is formed by vacuum forming on a component (preform) that has a common structure formed by injection molding and can be attached to various containers. Molds used in vacuum forming are often manufactured by cutting metal or resin blocks, and are less complex in structure than molds used in injection molding, so their manufacturing costs are not as high. However, there is still room for improvement in this method, as the strength of the vacuum formed part is not as high as that of other parts.

[0004] Regarding technology for increasing the strength of parts formed by vacuum forming, Patent Document 1 discloses an invention entitled "Composite molded product and manufacturing method thereof," which relates to a composite molded product consisting of a core material used as a mold for vacuum forming and a skin material integrally molded on top of this core material, and a method for manufacturing the same. The method for manufacturing a composite molded product disclosed in Patent Document 1 is to produce a composite molded product consisting of a skin material made of non-foamed thermoplastic resin and a core material made of foamed thermoplastic resin by using a core material formed by foaming a thermoplastic resin as a vacuum forming mold and integrally molding a thermoplastic resin onto the core material. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-103165 Summary of the Invention [Problem to be solved by the invention]

[0006] When the manufacturing method for composite molded products disclosed in Patent Document 1 is applied to a support member for a transport container, the strength of the portion formed by vacuum molding to support the article can be increased, but the core material cannot be manufactured inexpensively and in a short time, which may ultimately increase the manufacturing cost of the support member. Patent Document 1 also describes that the core material formed by foam molding has tiny gaps that function as suction holes when removing air from the mold during vacuum molding. However, these gaps are too small and too complex to be used as suction holes, making it difficult for the manufacturing method for composite molded products disclosed in Patent Document 1 to reliably adsorb the object to be molded to the surface of the core material. Therefore, this method requires additional machining of the above-mentioned suction holes into the core material.

[0007] The present invention has been made to address the issues with such composite molded products, and aims to provide a composite molded product and a manufacturing method thereof that, when applied to a receiving member for a transport container, can increase the strength of the part that supports the article and reduce manufacturing costs. [Means for solving the problem]

[0008] In order to achieve the above object, the first invention is a composite molded product manufactured by a vacuum molding method in which a molding object made of a plastic plate or sheet material is heated and softened, and then the object is attached to a core material in a softened state to form a skin material, and the composite molded product is characterized by comprising a core material made of multiple plate materials joined or connected together as a single unit, and a skin material formed on the surface of the core material.

[0009] A second invention is characterized in that, in the first invention, a connector is provided for connecting and integrating a plurality of plate materials.

[0010] A third invention is characterized in that in the second invention, the plate material has a corrugated cardboard structure.

[0011] The fourth invention is a method for producing a composite molded product according to any one of the first to third inventions, characterized in that after vacuum forming an object to be molded placed in a thermoforming device, the core material with a skin material formed on its surface is removed from the thermoforming device. [Effects of the Invention]

[0012] In the first invention, the core material is made up of multiple integrated plate materials, and when determining the shape of the core material, only two-dimensional data showing the shape of the plate materials is required, rather than the conventional three-dimensional data showing the shape of the entire core material, making it easy to design the core material. Furthermore, according to the first invention, when changing part of the shape of the core material, it is only necessary to rearrange some of the plate materials, and there is no need to remake the entire core material, making it possible to flexibly respond to requests for changes or modifications to the shape of the core material.

[0013] Furthermore, when multiple plates constituting the core material are connected, the gaps between the plates function as suction holes during vacuum forming, eliminating the need for additional suction holes in the core material. Therefore, the additional suction holes do not reduce the strength of the core material. In particular, in the first invention, the gaps are connected in all directions, up, down, left, and right. Unlike core materials made of foamed thermoplastic resins, which have complex air flow paths, the air flow paths are ensured over a wide area during vacuum forming, ensuring reliable suction hole function. As a result, the accuracy of vacuum forming is stable. Furthermore, the first invention can handle molded products with thin-walled shapes, which are dimensionally limited by conventional vacuum forming methods requiring a gradient for release, and molded products with complex shapes such as undercuts, which are difficult to vacuum form because suction holes are only provided in the vertical direction. While it is typically difficult to add ribs for reinforcement to thin-walled shapes in vacuum forming, in the first invention, the plates act to increase the strength of the core material.

[0014] Furthermore, according to the first invention, during vacuum forming, a portion of the object to be formed is sucked into the gaps between the connected plates, thereby increasing the bonding strength of the skin material to the core material. In addition, when the first invention is used as a support member for a transport container, by appropriately changing the materials of the core material and the skin material, the strength and surface characteristics corresponding to the items stored in the transport container can be imparted to the part supporting the items.

[0015] In the second invention, the multiple plate materials that make up the core material are integrated by connectors, which, in addition to the effects of the first invention, has the advantage that, unlike when the plate materials are glued together, there is no need to clean up the excess adhesive and there is no need to wait for the adhesive to harden before the next process. Furthermore, since there is no foreign substance such as adhesive, if the core material and the object to be molded are made of the same material, recycling and reuse are possible. Furthermore, according to the second invention, the connection between the multiple plate materials can be easily released by removing the connectors, which has the effect of allowing the work of rearranging some of the plate materials to change the shape of the core material to be carried out efficiently in a short time.

[0016] In core materials made up of multiple plate materials, the gaps between the plate materials function as suction holes during vacuum forming, but in the third invention, the hollow parts in the plate materials with a corrugated cardboard structure also function as suction holes during vacuum forming, so that the object to be formed is adsorbed to the core material reliably and with high precision during vacuum forming.

[0017] In the fourth invention, the effects of the invention that are exhibited in the composite molded article according to any one of the first to third inventions are exhibited in the same way. [Brief explanation of the drawings]

[0018] [Figure 1] FIG. 1(a) is an external perspective view of a composite molded product according to an embodiment of the present invention, and FIG. 1(b) is a cross-sectional view taken along line AA in FIG. 1(a). [Figure 2] 1(a) is an external perspective view of the core material constituting the composite molded product shown in FIG. 1(a), and (b) and (c) are external perspective views of the first plate material and the second plate material shown in FIG. 1(a), respectively. [Figure 3] 1(a) and 1(b) are external perspective views of a first member and a second member that constitute a connector, respectively, and 1(c) is a side view of the second member. [Figure 4] 1 is a process diagram illustrating a method for producing a composite molded product according to the present invention. [Figure 5]1A and 1B are an external perspective view and a cross-sectional view, respectively, of a positioning jig for a composite molded product. [Figure 6] 2(a) and (b) are external perspective views of the first and second modified examples of the core material shown in FIG. 2(a), respectively, and (c) and (d) are external perspective views of the first and second plate materials shown in FIG. 2(b), respectively. [Figure 7] 2(a) is an external perspective view of a third modified example of the core material shown in FIG. 2(a), and (b) to (d) are external perspective views of the first to third plate materials shown in FIG. 2(a), respectively. DETAILED DESCRIPTION OF THE INVENTION [Example]

[0019] The composite molded product and its manufacturing method of the present invention will be specifically described with reference to Figures 1 to 7. In Figure 2(a), in order to avoid cluttering the drawing, only some of the plate materials are labeled with reference numerals indicating that they are the first plate material or the second plate material. As shown in Figures 1(a) and 1(b), a composite molded product 1a according to an embodiment of the present invention is called "plastic corrugated cardboard" and comprises a core material 4 having a structure in which a plurality of plate-shaped materials 2, which are manufactured using polypropylene resin as a raw material and have a hollow structure similar to that of paper corrugated cardboard, are integrated together with connectors 3, and a skin material 5 formed by vacuum molding using this core material 4 as a mold, and a convex composite molded portion 6a made of the core material 4 and the skin material 5 is formed in a part of a preform 6 formed by injection molding.

[0020] As shown in Figures 2(a) to 2(c), the plate materials 2 that make up the core material 4 consist of four first plate materials 7 and two second plate materials 8, and each of these plate materials 2 has an opening 4a for attaching a connector 3. The multiple plates 2 constituting the core material 4 are not joined to each other and are arranged so as to be overlapped in the plate thickness direction with a gap therebetween that does not allow the skin material 5 to completely flow in between them. The number of each of the first plate materials 7 and second plate materials 8 can be changed as appropriate depending on the application of this composite molded product 1a.

[0021] In this way, in the composite molded product 1a, the core material 4 is composed of multiple integrated plate materials 2, so when determining the shape of the core material 4, only two-dimensional data showing the shapes of the first plate material 7 and the second plate material 8 is required, and three-dimensional data showing the overall shape of the core material 4 is not required as in the conventional case, making it easy to design the core material 4. Furthermore, with the composite molded product 1a, when changing part of the shape of the core material 4, it is only necessary to rearrange part of the plate material 2, and there is no need to remake the entire core material 4, so it is possible to flexibly respond to requests for changing or modifying the shape of the core material. Furthermore, in the composite molded product 1a, the hollow portions in the plate material 2 having the corrugated cardboard structure function as suction holes during vacuum forming, so there is no need to separately process suction holes in the core material 4. Therefore, there is no phenomenon in which the strength of the core material 4 is reduced due to additional processing of suction holes. In addition, the composite molded product 1a has the effect of shortening the time required to manufacture the core material 4.

[0022] Furthermore, in the composite molded product 1a, not only the hollow portions of the plate materials 2 but also the gaps between the plate materials 2 function as suction holes during vacuum forming. In particular, these gaps are connected in all directions, including up, down, left, and right. Unlike the core material made of foamed thermoplastic resin disclosed in Patent Document 1, which has complex air flow paths, the air flow paths are formed over a wide area during vacuum forming, ensuring reliable suction hole function. As a result, the accuracy of vacuum forming is stable. Furthermore, the composite molded product 1a with this structure can be used to mold thin-walled shapes, which are dimensionally limited by conventional vacuum forming methods that require a gradient for release, and complex shapes such as undercuts, which are difficult to vacuum form because suction holes are only provided in the vertical direction. Normally, it is difficult to provide a rib structure for reinforcement in thin-walled shapes during vacuum forming. However, in the composite molded product 1a, the plate materials 2 act to increase the strength of the core material 4.

[0023] Furthermore, in the composite molded product 1a, during vacuum molding, part of the object to be molded is sucked into the gaps between the multiple connected plate materials 2, which is expected to increase the bonding strength of the skin material 5 to the core material 4. Additionally, in the composite molded product 1a, the multiple plate materials 2 that make up the core material 4 are integrated with the connectors 3, which has the advantage that, unlike when the plate materials 2 are glued together, there is no need to deal with excess adhesive, and there is no need to wait until the adhesive hardens before proceeding to the next step. Also, because there is no foreign substance such as adhesive, if the core material 4 and the object to be molded are made of the same material, recycling and reuse are possible.

[0024] The connector 3 is a plate connector according to a patent (Patent No. 7007767) held by the applicant of the present application, and is composed of a first member 9 and a second member 13 as shown in Figures 3(a) and 3(b). The first member 9 has a first base plate 10 having a jig insertion opening 10a whose inner peripheral surface has a circular outline, a pair of guide plates 11, 11 arranged parallel to each other and symmetrically on the inner surface 10b of the first base plate 10 with the jig insertion opening 10a in between, and engagement portions 11a to 11c arranged in pairs on opposing surfaces 11d, 11d of the pair of guide plates 11, 11 so as to protrude in a direction parallel to the first base plate 10. The tips of the pair of guide plates 11, 11 are connected to each other via a rod-shaped body 12 whose width in a direction parallel to both the first base plate 10 and the guide plate 11 is narrower than the width of the engagement portions 11a to 11c.

[0025] The second member 13 is made of a flat plate material having a generally rectangular shape in a plan view, and has a pair of engaging claws 14, 14 arranged parallel to each other, and a second base plate 15 having the engaging claws 14, 14 erected on an inner surface 15a thereof. The engaging claw 14 has a protruding portion 14a formed so as to be able to engage with the engaging portions 11a to 11c of the first member 9, and an inclined portion 14b formed so as to have a tapered shape from the protruding portion 14a to a tip 14c, and is structured so that the engagement state of the protruding portion 14a with the engaging portions 11a to 11c is released by elastic deformation.

[0026] When the pair of engaging claws 14, 14 are not elastically deformed, the distance between the opposing surfaces 14d, 14d is longer than the width of the engaging portions 11a to 11c of the first member 9, and the distance between the back surfaces 14e, 14e is shorter than the width of the guide plate 11 (the length parallel to the first base plate 10). The width of the engaging claws 14 (the length parallel to the second base plate 15) is shorter than the distance between the opposing surfaces 11d, 11d of the guide plates 11, 11. The convex portion 14a protrudes inward so as to be engageable with the engaging portions 11a to 11c when the second base plate 15 is parallel to the first base plate 10 and the pair of engaging claws 14, 14 are disposed between the pair of guide plates 11, 11 so as to sandwich the engaging portions 11a to 11c from both sides. That is, when the engaging claws 14 are not elastically deformed, the distance between the protrusions 14a is shorter than the width of the engaging portions 11a to 11c.

[0027] In the connector 3, when the pair of guide plates 11, 11 of the first member 9 communicate with the openings 4a (see FIGS. 2(b) and 2(c)) of the first plate 7 and the second plate 8, and the second member 13 is moved closer to the first member 9 while the second base plate 15 remains parallel to the first base plate 10, the pair of engaging claws 14, 14 elastically deform in directions in which the tips 14c, 14c move away from each other, increasing the distance between the protrusions 14a, 14a. Then, when the protrusions 14a, 14a pass the point where the width of the pair of engaging portions 11a, 11a is at its maximum, the pair of engaging claws 14, 14 recover from the elastic deformation and return to their original shape. As a result, the protrusions 14a, 14a engage with the flat portions of either of the pair of engaging portions 11a, 11a-11c, 11c. As a result, the second member 13 is connected to the first member 9, and the first plate member 7 and the second plate member 8 are connected via the first member 9 and the second member 13.

[0028] On the other hand, if a rod-shaped tool or the like is inserted through the jig insertion opening 10a in this state and the tip of the tool is pressed against the inclined portions 14b, 14b of the pair of engaging claws 14, 14, the pair of engaging claws 14, 14 will elastically deform so as to bend toward the back surfaces 14e, 14e, and the tips 14c, 14c will move in directions away from each other. This releases the engagement between the first member 9 and the second member 13, allowing the connector 3 to be removed from the first plate material 7 and the second plate material 8.

[0029] In this way, in the composite molded product 1a, the connected state of the multiple plate materials 2 can be easily released by removing the connectors 3, so the work of rearranging some of the plate materials 2 in order to change the shape of the core material 4 can be carried out efficiently in a short time. Furthermore, in the composite molded product 1a, when the connectors 3 are removed and the first plate material 7 and the second plate material 8 are separated, the core material 4 becomes easily separable from the skin material 5, so that the work of separating and disposing of the core material 4 after use can be carried out efficiently.

[0030] Here, a method for manufacturing the composite molded product 1a will be described with reference to FIG. As shown in FIG. 4, first, a substantially rectangular preform 6 is formed by injection molding a thermoplastic resin (step S1). Next, the preform 6 is placed in a heating booth of a thermoforming device, and the molding target portion of the preform 6 is heated until it reaches a predetermined heat distortion temperature (step S2). After placing the heated preform 6 in the thermoforming device, the core material 4 is pressed from below against the bottom surface of the molding target portion while suctioning air present in the space between the preform 6 and the core material 4, and a plug is pressed from above against the top surface of the molding target portion (step S3). Finally, after the preform 6 has been sufficiently cooled, the core material 4 with the skin material 5 formed on its surface is removed from the thermoforming device (step S4). According to such a method for manufacturing a composite molded article, the effects of the invention that are exhibited in the composite molded article 1a already explained can be similarly exhibited.

[0031] In the above-mentioned step S3, it is necessary to position the core material 4 relative to the molding target portion of the preform 6. At this time, in the composite molded product 1a, by omitting the tip pin in the mold related to the patent (Patent No. 7333682) held by the applicant of the present application, the mold can be used as a positioning jig. The positioning jig for the composite molded product will now be described with reference to Figures 5(a) and 5(b). Figure 5(b) shows the positioning jig, first pin, and second pin cut along a plane passing through the central axis of the pin insertion hole. To avoid cluttering the illustration, Figure 5(b) only partially labels the male and female threads of the connecting pin and the through hole in the bottom plate, and shows a state in which a bolt is attached to only one first pin.

[0032] 5(a) and 5(b), the positioning jig 16 is made up of a substantially rectangular parallelepiped base 19 having a recess 19c in a bottom surface 19b and having the first pin 17 and the second pin 18 mounted thereon, and a bottom plate 20 fitted into the recess 19c and fixed to the base 19 with bolts (not shown). The base 19 also has a plurality of pin insertion holes 19d that are circular in plan view and are formed perpendicular to the top surface 19a.

[0033] The first pin 17 is made of a cylindrical body with a male screw portion 17a at its tip end that protrudes in the longitudinal direction, and a female screw portion 17b at its base end that extends parallel to the longitudinal direction and that screws onto the bolt 21. The second pin 18 is made of a cylindrical body with a length equal to the depth of the pin insertion hole 19d and with a female screw portion 18a that screws onto the bolt 21 that extends parallel to the longitudinal direction, and is configured so that it can be installed inside the pin insertion hole 19d of the base 19 in order to close the pin insertion hole 19d. On the other hand, the bottom plate 20 has a plurality of through holes 20a, which are circular in plan view and parallel to the thickness direction at locations that coincide with the pin insertion holes 19d, so that bolts 21 can be inserted into the pin insertion holes 19d of the base 19.

[0034] In the positioning jig 16 having such a structure, when the male screw portion 17a provided at the tip of the first pin 17 is inserted into the hollow portion of the first plate material 7 or the second plate material 8, the composite molded product 1a is fixed to the upper surface 19a of the base 19. Then, by placing the positioning jig 16 in this state at a predetermined location below the preform 6, the core material 4 is accurately positioned relative to the preform 6. In other words, the use of the positioning member 16 makes it easy to position the composite molded product 1a relative to the preform 6, which provides excellent workability when vacuum forming. In the positioning member 16, the first pin 17 does not have to be provided with the male screw portion 17a at its tip, as long as the tip has a structure that allows it to be inserted into the hollow portion of the first plate material 7 or the second plate material 8. Even in the case of a plate material that does not have a hollow structure, such as plastic corrugated cardboard, the above-mentioned effect can be similarly achieved if a portion into which the male screw portion 17a can be inserted is provided at the bottom.

[0035] The composite molded product of the present invention is not limited to the above structure. For example, instead of "plastic corrugated cardboard," the plate material 2 constituting the core material 4 can be made of a closed-cell sheet called "Palonia (registered trademark)," which is made by extruding and foaming polypropylene at approximately three times its original size. Unlike plastic corrugated cardboard, the plate material 2 made of Paronia does not have any hollow spaces that function as suction holes during vacuum forming. However, if the plate materials 2 are connected by connectors 3 or the like, the gaps between the plate materials 2 function as suction holes during vacuum forming.

[0036] Furthermore, for example, instead of the plastic core material 4, composite molded products 1b and 1c may be provided with wooden core materials 22 and 23 as shown in Figs. 6(a) and 6(b). As shown in Fig. 6(a), the core material 22 has a structure in which a plurality of wooden plates 24 of different shapes, namely, a first plate 25 and a second plate 26, are integrated by bonding. On the other hand, as shown in Figs. 6(b) to 6(d), the core material 23 has a structure in which a plurality of wooden plates 27 of different shapes, namely, a first plate 28 and a second plate 29, are integrated by connectors 3, and each of the plates 27 has an opening 23a for attaching the connector 3. The plurality of plates 27 that make up the core material 23 are not joined to each other, and are arranged so as to be overlapped in the thickness direction with a gap therebetween that is large enough to prevent the skin material 5 from completely flowing between them.

[0037] In this way, when core materials 22, 23 are used instead of core material 4 of composite molded product 1a, the strength of composite molded portion 6a changes. On the other hand, when the material of skin material 5 is changed in composite molded product 1a, its surface characteristics change. In composite molded product 1a, the materials of core material 4 and skin material 5 can be changed as appropriate. Therefore, when composite molded product 1a is used as a receiving member for a transport container, by appropriately changing the materials of core material 4 and skin material 5, the effect is achieved in that the strength and surface characteristics appropriate for the article to be stored in the transport container are imparted to the portion that supports the article.

[0038] Furthermore, for example, as shown in Fig. 7(a), a composite molded product 1d including a core material 30 can be used instead of the composite molded product 1a including the core material 4. In Fig. 7(a), in order to avoid the illustration becoming complicated, only some of the plate materials are given reference numerals indicating that they are the first plate material or the second plate material. As shown in FIGS. 7(b) to 7(d), the core material 30 is composed of multiple plastic plates 31 of different shapes, namely, a first plate 32, a second plate 33, and a third plate 34. The first plate 32 and the second plate 33 are arranged so as to be stacked in the plate thickness direction, and each has a notch 32a, 33a into which the third plate 34 can be simultaneously inserted. That is, the core material 30 has a structure in which the first plate 32 and the second plate 33 are stacked in the plate thickness direction without being joined to each other, with a gap large enough to prevent the skin material 5 from completely flowing between them, and are connected together via the third plate 34 simultaneously inserted into the notches 32a, 33a. The first plate 32 and the second plate 33 can be easily separated by removing the third plate 34 through the notches 32a, 33a.

[0039] In this way, in the composite molded product 1d, the connection between the first plate material 32 and the second plate material 33 can be easily released by removing the third plate material 34, so the task of rearranging some of the plate materials 31 in order to change the shape of the core material 30 can be performed efficiently in a short time. Also, in the composite molded product 1d, when the third plate material 34 is removed and the first plate material 32 and the second plate material 33 are separated, the core material 30 becomes easily separable from the skin material 5, so that sorting and disposal work after use can be performed efficiently. Furthermore, because the composite molded product 1d does not contain a foreign substance such as an adhesive, it can be recycled or reused if the core material 30 and the molded object are made of the same material. [Industrial Applicability]

[0040] The composite molded article of the present invention can be used as a support member that is installed inside a transport container to support parts or products. [Explanation of symbols]

[0041] DESCRIPTION OF SYMBOLS 1a to 1d... Composite molded product 2... Plate material 3... Connector 4... Core material 4a... Opening 5... Skin material 6... Preform 6a... Composite molded portion 7... First plate material 8... Second plate material 9... First member 10... First base plate 10a... Jig insertion hole 10b... Inner surface 10c... Outer surface 11... Guide plate 11a to 11c... Engagement portion 11d... Opposing surface 12... Rod-shaped body 13... Second member 14... Engagement claw 14a... Convex portion 14b... Inclined portion 14c... Tip 14d... Opposing surface 14e... Rear surface 15... Second base plate 15a... Inner surface 16... Positioning jig 17... First pin 17a... Male thread portion 17b... Female thread portion 18... Second pin 18a... Female thread portion 19...Base 19a...Top surface 19b...Bottom surface 19c...Recess 19d...Pin insertion hole 20...Bottom plate 20a...Through hole 21...Bolt 22, 23...Core material 23a...Opening 24...Plate material 25...First plate material 26...Second plate material 27...Plate material 28...First plate material 29...Second plate material 30...Core material 31...Plate material 32...First plate material 32a...Notch 33...Second plate material 33a...Notch 34...Third plate material

Claims

1. A composite molded product formed by adhering a skin material made of a plastic plate or sheet material to a core material, A connector that connects and integrates a plurality of plate materials; the core material consisting of a plurality of the plate materials integrated by the connector; and the skin material formed on the surface of the composite molded product.

2. 2. The composite molded product according to claim 1, wherein the plate material has a corrugated cardboard structure.

3. A method for producing the composite molded product according to claim 1 or claim 2, a first step of forming a core material by connecting and integrating a plurality of plate materials with connecting tools; a second step of placing a molding object made of a plastic plate or sheet material in a thermoforming device and heating and softening it; a third step of adsorbing the object to be molded onto the surface of the core material in the thermoforming device; and a fourth step of removing the core material with the skin material formed on the surface thereof from the thermoforming device together with the core material.

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